Emerson 7003M User Manual

Operator Manual

748223-K
June 2002

Model 7003M

Percent Oxygen Analyzer

http://www.processanalytic.com

ESSENTIAL INSTRUCTIONS

READ THIS PAGE BEFORE PROCEEDING!

Rosemount Analytical designs, manufactures and tests its products to meet many national and
international standards. Because these instruments are sophisticated technical products, you
MUST properly install, use, and maintain them to ensure they continue to operate within their
normal specifications. The following instructions MUST be adhered to and integrated into your
safety program when installing, using, and maintaining Rosemount Analytical products. Failure to
follow the proper instructions may cause any one of the following situations to occur: Loss of life;
personal injury; property damage; damage to this instrument; and warranty invalidation.

• Read all instructions prior to installing, operating, and servicing the product.

• If you do not understand any of the instructions, contact your Rosemount Analytical rep-

resentative for clarification.

• Follow all warnings, cautions, and instructions marked on and supplied with the product.

• Inform and educate your personnel in the proper installation, operation, and maintenance of

the product.

• Install your equipment as specified in the Installation Instructions of the appropriate Instruc-
tion Manual and per applicable local and national codes. Connect all products to the proper
electrical and pressure sources.

• To ensure proper performance, use qualified personnel to install, operate, update, program,
and maintain the product.

• When replacement parts are required, ensure that qualified people use replacement parts
specified by Rosemount. Unauthorized parts and procedures can affect the product’s per­formance, place the safe operation of your process at risk, and VOID YOUR WARRANTY.
Look-alike substitutions may result in fire, electrical hazards, or improper operation.

• Ensure that all equipment doors are closed and protective covers are in place, except when
maintenance is being performed by qualified persons, to prevent electrical shock and per­sonal injury.

The information contained in this document is subject to change without notice.

Ryton® is a registered trademark of Phillips Petroleum Co.

Emerson Process Management

Rosemount Analytical Inc.
Process Analytic Division

1201 N. Main St.
Orrville, OH 44667-0901
T [phone]
F [phone]
e-mail: [e-mail]

http://www.processanalytic.com

Model 7003M

PREFACE...........................................................................................................................................P-1

Definitions ...........................................................................................................................................P-1

Safety Summary .................................................................................................................................P-2

Documentation....................................................................................................................................P-5

Compliances .......................................................................................................................................P-5

1-0 DESCRIPTION AND SPECIFICATIONS..............................................................................1-1

1-1 Overview................................................................................................................................1-1

1-2 Principle of Measurement......................................................................................................1-1

1-3 Sensors..................................................................................................................................1-1

1-4 Conditions Affecting Measurement .......................................................................................1-2

a. Gas Composition.............................................................................................................1-2

b. Sample and Cal Gas Pressures......................................................................................1-2

c. Environmental Factors ....................................................................................................1-2

1-5 Features.................................................................................................................................1-3

1-6 Specifications ........................................................................................................................1-4

a. Performance....................................................................................................................1-4

b. Physical...........................................................................................................................1-4

c. Electrical..........................................................................................................................1-5

d. Sensors ...........................................................................................................................1-5

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TABLE OF CONTENTS

2-0 INSTALLATION ....................................................................................................................2-1

2-1 Unpacking..............................................................................................................................2-1

2-2 Storage ..................................................................................................................................2-1

2-3 Analyzer Installation ..............................................................................................................2-1

2-4 Sensor Installation .................................................................................................................2-1

a. Analyzer/Sensor Jumper Configuration ..........................................................................2-1

2-5 Electrical Connections ...........................................................................................................2-3

a. Sensor Cable ..................................................................................................................2-4

b. Power Connections.........................................................................................................2-4

c. Current Output Connections ...........................................................................................2-6

d. Voltage Output Connections ...........................................................................................2-6

2-6 Relay Contacts for Alarms or ON/OFF-Controls ...................................................................2-8

3-0 OPERATION .........................................................................................................................3-1

3-1 Overview................................................................................................................................3-1

3-2 Keypad Operation..................................................................................................................3-1

a. Single and Double Keystroke..........................................................................................3-3

b. Display Prompts ..............................................................................................................3-4

c. Error Messages...............................................................................................................3-6

d. Automatic Return to RUN Mode .....................................................................................3-7

e. Preventing Unauthorized Access....................................................................................3-7

f. Sensor Equilibrium..........................................................................................................3-7

3-3 Start-Up .................................................................................................................................3-8

a. Initial Power-Up...............................................................................................................3-8

b. System Restart................................................................................................................3-9

c. Automatic Restart - Due to Power Failure ......................................................................3-9

d. Manual Restart................................................................................................................3-9

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3-4 Run Mode ..............................................................................................................................3-10

a. Display Oxygen Concentration/Sensor Temperature .....................................................3-10

b. Acknowledge Alarms ......................................................................................................3-10

c. Access Other Modes.......................................................................................................3-10

3-5 Setup Mode ...........................................................................................................................3-11

a. Security Code..................................................................................................................3-13

b. Current Output Range - 0-20mA or 4-20mA................................................................3-13

c. Range Endpoint Adjustments .........................................................................................3-13

d. Zero Offset Adjustment ...................................................................................................3-15

3-6 Alarm Mode vs. ON/OFF-Control Mode ................................................................................3-16

a. Relay Configured as Alarm .............................................................................................3-16

b. Relay Configured as ON/OFF-Controller ........................................................................3-16

c. Relay Contacts................................................................................................................3-18

d. Fail Safe Operation .........................................................................................................3-18

e. Relay Reset Upon Fatal Error.........................................................................................3-18

f. Pressure Effects on Alarms ............................................................................................3-18

g. Setting Alarm and ON/OFF-Controller Relays................................................................3-18

h. Setting Alarm Setpoints ..................................................................................................3-18

i. Setting Alarm ON and OFF Levels .................................................................................3-19

Model 7003M

4-0 CALIBRATION AND ADJUSTMENTS.................................................................................4-1

4-1 Frequency of Calibration .......................................................................................................4-1

4-2 Calibration mode ...................................................................................................................4-1

a. Zero Calibration...............................................................................................................4-1

b. Span Calibration..............................................................................................................4-1

c. Pressure Compensation - Correction for Constant Pressure Differences......................4-4

4-3 Hold Mode .............................................................................................................................4-5

4-4 Diagnostics Mode ..................................................................................................................4-8

a. Raw Sensor Voltage .......................................................................................................4-8

b. Test Current Output ........................................................................................................4-8

c. Linearizing Current Output ..............................................................................................4-8

d. Test Alarm Relays...........................................................................................................4-10

4-5 Adjustments And Settings .....................................................................................................4-10

5-0 THEORY................................................................................................................................5-1

5-1 Principles Of Operation .........................................................................................................5-1

a. Electrochemical Theory ..................................................................................................5-1

5-2 Effects of Sample Conditions ................................................................................................5-1

a. Barometric Pressure .......................................................................................................5-1

b. Humidity ..........................................................................................................................5-1

c. Sample Temperature ......................................................................................................5-1

d. Interfering Gases.............................................................................................................5-2

5-3 Circuit Descriptions................................................................................................................5-2

a. Signal Board....................................................................................................................5-2

b. Power Supply Board .......................................................................................................5-2

c. Microprocessor Board .....................................................................................................5-2

d. Alarm Circuits..................................................................................................................5-2

6-0 ROUTINE SERVICING AND TROUBLESHOOTING...........................................................6-1

6-1 Routine Servicing ..................................................................................................................6-1

6-2 Troubleshooting.....................................................................................................................6-1

a. Symptoms .......................................................................................................................6-1

ii Contents Rosemount Analytical Inc. A Division of Emerson Process Management

Model 7003M

7-0 REPLACEMENT PARTS ......................................................................................................7-1

7-1 Circuit Board Replacement Policy .........................................................................................7-1

7-2 Matrix .....................................................................................................................................7-1

7-3 Replacement Parts - Model 7003M.......................................................................................7-2

7-4 Replacement Parts - Sensors................................................................................................7-3

a. Rechargeable Sensors ...................................................................................................7-3

b. Disposable Sensors ........................................................................................................7-4

8-0 RETURN OF MATERIAL ......................................................................................................8-1

8-1 Return Of Material .................................................................................................................8-1

8-2 Customer Service ..................................................................................................................8-1

8-3 Training..................................................................................................................................8-1

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LIST OF ILLUSTRATIONS

Figure 2-1. Sensor Ordering Matrix.......................................................................................... 2-2

Figure 2-2. Model 7003M Rear Panel Connections................................................................. 2-3

Figure 2-3. Power Jumpers and Fuses .................................................................................... 2-5

Figure 2-4. Current Output Connections .................................................................................. 2-7

Figure 3-1. Model 7003M Front Panel Controls and Indicators ............................................... 3-1

Figure 3-2. Model 7003M Operation Flow Diagram................................................................. 3-2

Figure 3-3. SETUP Mode Flowchart ...................................................................................... 3-12

Figure 3-4. Security Access Routine Flowchart ..................................................................... 3-14

Figure 3-5. ALARM Mode Flowchart...................................................................................... 3-17

Figure 3-6. Action of Alarm Relay ON and OFF Setpoints .................................................... 3-19

Figure 4-1. CALIBRATION Mode and PRESSURE COMPENSATION Flowchart.................. 4-3

Figure 4-2. HOLD and DIAGNOSTICS Modes Flowchart ....................................................... 4-7

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Table 2-1. Sensor Cables ....................................................................................................... 2-4

Table 2-2. Analyzer Cable Connections ................................................................................. 2-4

Table 3-1. Key Functions ........................................................................................................ 3-3

Table 3-2. Display Indicators .................................................................................................. 3-3

Table 3-3. Security Access Prompts and Responses............................................................. 3-4

Table 3-4. Alarm Settings Prompts and Responses............................................................... 3-4

Table 3-5. Calibration Prompts and Responses ..................................................................... 3-4

Table 3-6. System Setup Prompts and Responses................................................................ 3-4

Table 3-7. System Hold and Diagnostics Codes .................................................................... 3-5

Table 3-8. Data Displayed in DIAGNOSTICS Mode............................................................... 3-5

Table 3-9. Miscellaneous Prompts and Responses ............................................................... 3-5

Table 3-10. Power ON, Reset Diagnostics Errors (Fatal Errors ............................................... 3-6

Table 3-11. RUN Mode Errors (Non-Fatal Errors ..................................................................... 3-6

Table 3-12. Signal Board Errors ............................................................................................... 3-6

Table 3-13. Microprocessor Errors That Reset The System .................................................... 3-6

Table 3-14. Default Settings at Power-Up ................................................................................ 3-8

Table 3-15. RUN Mode Key Functions ................................................................................... 3-10

Table 3-16. SETUP Mode Key Functions .............................................................................. 3-11

Table 3-17. ALARM Mode Key Functions.............................................................................. 3-16

Table 3-18. Alarm Relay Contact Positions/Terminal Locations............................................. 3-18

Table 4-1. CALIBRATION Mode Key Functions........................................................................1

Table 4-2. Composition of Dry Atmospheric Air...................................................................... 4-2

Table 4-3. Composition of Humid Atmospheric Air................................................................. 4-2

Table 4-4. Barometric Pressure Effect on Apparent Oxygen Concentration ..............................4

Table 4-5. PRESSURE COMPENSATION Mode Key Functions..............................................4

Table 4-6. HOLD Mode Key Functions ......................................................................................5

Table 4-7. Caret Readings...................................................................................................... 4-6

Table 4-8. DIAGNOSTICS Mode Key Functions ................................................................... 4-8

Model 7003M

LIST OF TABLES

LIST OF DRAWINGS

652542 Outline and Mounting – Panel Mount
652543 Outline and Mounting – Wall Mount
652544 Outline and Mounting – Pipe Mount
652682 Pictorial Wiring Diagram
652683 Interconnect Diagram
652699 Installation Drawing

iv Contents Rosemount Analytical Inc. A Division of Emerson Process Management

Operator Manual

Model 7003M

PREFACE

The purpose of this manual is to provide information concerning the components,
functions, installation and maintenance of the Model 7003M Percent Oxygen Analyzer

Some sections may describe equipment not used in your configuration. The user should
become thoroughly familiar with the operation of this module before operating it. Read
this instruction manual completely.

DEFINITIONS

The following definitions apply to DANGERS, WARNINGS, CAUTIONS and NOTES found throughout
this publication.

DANGER .

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June 2002

Highlights the presence of a hazard which will cause severe personal injury, death, or substantial
property damage if the warning is ignored.

WARNING .

Highlights an operation or maintenance procedure, practice, condition, statement, etc. If not
strictly observed, could result in injury, death, or long-term health hazards of personnel.

CAUTION.

Highlights an operation or maintenance procedure, practice, condition, statement, etc. If not
strictly observed, could result in damage to or destruction of equipment, or loss of effectiveness.

NOTE

Highlights an essential operating procedure,
condition or statement.

Rosemount Analytical Inc. A Division of Emerson Process Management Preface P-1

Operator Manual

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Model 7003M

SAFETY SUMMARY

If this equipment is used in a manner not specified in these instructions, protective systems may be
impaired.

AUTHORIZED PERSONNEL

To avoid explosion, loss of life, personal injury and damage to this equipment and on-site property,
all personnel authorized to install, operate and service the this equipment should be thoroughly
familiar with and strictly follow the instructions in this manual. SAVE THESE INSTRUCTIONS.

DANGER.

ELECTRICAL SHOCK HAZARD

Do not operate without doors and covers secure. Servicing requires access to live parts which can
cause death or serious injury. Refer servicing to qualified personnel.

For safety and proper performance this instrument must be connected to a properly grounded
three-wire source of power.

Relay contacts wired to separate power sources must be disconnected before servicing.

This instrument was shipped from the factory set up to operate on either 115 VAC 50/60 Hz, or 230
VAC 50/60 Hz, as specified by sales order. Verification that this voltage is proper for the installation
is the responsibility of the purchaser. See Section 2-5b on page 2-4.

WARNING .

OXYGEN LEVEL WILL NOT BE MONITORED

The instrument will not return automatically to the RUN mode from HOLD or DIAGNOSTICS modes.
Operator must manually return instrument to RUN mode to continue monitoring oxygen.

WARNING.

ERRONEOUS OXYGEN READINGS

If the pressure compensation function is not applied correctly, erroneous readings can be dis­played. The display using span gas during calibration should be the same as the reading using the
same gas in RUN mode if the pressure values are correctly entered.

P-2 Preface Rosemount Analytical Inc. A Division of Emerson Process Management

Operator Manual

Model 7003M

WARNING.

PARTS INTEGRITY

Tampering or unauthorized substitution of components may adversely affect safety of this product.
Use only factory documented components for repair

WARNING.

SENSOR NOT INTRINSICALLY SAFE

The oxygen sensors used with this analyzer are not intrinsically safe. Use of the sensors in or near
flammable liquids, gases or vapors or in Class I, Division 1, Hazardous Locations should be care­fully evaluated by qualified personnel at the site and is entirely the responsibility of the user.

The sensor is approved as non-incendive for use in Class I, Division 2 locations.

CAUTION .

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HIGH PRESSURE GAS CYLINDERS

This module requires periodic use of pressurized gas. See General Precautions for Handling and
Storing High Pressure Gas Cylinders, page P-4

Rosemount Analytical Inc. A Division of Emerson Process Management Preface P-3

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Model 7003M

GENERAL PRECAUTIONS FOR HANDLING AND STORING HIGH

PRESSURE GAS CYLINDERS

Edited from selected paragraphs of the Compressed Gas Association's "Handbook of Compressed
Gases" published in 1981

Compressed Gas Association
1235 Jefferson Davis Highway
Arlington, Virginia 22202

Used by Permission

1. Never drop cylinders or permit them to strike each other violently.

2. Cylinders may be stored in the open, but in such cases, should be protected against extremes of weather
and, to prevent rusting, from the dampness of the ground. Cylinders should be stored in the shade when lo­cated in areas where extreme temperatures are prevalent.

3. The valve protection cap should be left on each cylinder until it has been secured against a wall or bench, or
placed in a cylinder stand, and is ready to be used.

4. Avoid dragging, rolling, or sliding cylinders, even for a short distance; they should be moved by using a suit­able hand-truck.

5. Never tamper with safety devices in valves or cylinders.

6. Do not store full and empty cylinders together. Serious suckback can occur when an empty cylinder is at­tached to a pressurized system.

7. No part of cylinder should be subjected to a temperature higher than 125
permitted to come in contact with any part of a compressed gas cylinder.

8. Do not place cylinders where they may become part of an electric circuit. When electric arc welding, precau­tions must be taken to prevent striking an arc against the cylinder.

°

F (52°C). A flame should never be

P-4 Preface Rosemount Analytical Inc. A Division of Emerson Process Management

Operator Manual

Model 7003M

DOCUMENTATION

The following Model 7003M instruction materials are available. Contact Customer Service Center or the
local representative to order.

748223 Operator Manual (this document)

COMPLIANCES

The Model 7003M Percent Oxygen Analyzer and Models 4000 and 5000 series sensors are suitable for
use in Class I, Groups A, B, C, and D, Division 2 locations per North American electrical codes. Factory
Mutual Research (FM) approved under J.I. 1T5AO.AX. Canadian Standards Association (CSA) certified
under file LR 93812.

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FM

APPROVED

®

Rosemount Analytical Inc. A Division of Emerson Process Management Preface P-5

Operator Manual

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Model 7003M

P-6 Preface Rosemount Analytical Inc. A Division of Emerson Process Management

Model 7003M

Operator Manual

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June 2002

SECTION 1

DESCRIPTION AND SPECIFICATIONS

1-1 OVERVIEW

The Model 7003M Percent Oxygen Analyzer
continuously monitors the concentration of
oxygen in a gaseous sample. It consists of a
sensor and the analyzer. The sensor is
housed in a chamber assembly and is
connected to the analyzer by a shielded multi­conductor cable.

The Model 7003M Percent Oxygen Analyzer
provides direct digital readout, isolated current

MODE FUNCTION

RUN (see Section 3-4 on page 3-10) Normal monitoring
SETUP (see Section 3-5 on page 3-11) Changing parameters
ALARM/CONTROL (see Section 3-6 on page 3-16) Set alarms or ON/OFF controllers
CALIBRATION (see Section 4-2 on page 4-1) Gas calibration/pressure inputs
HOLD (see Section 4-3 on page 4-5) Retain last output value
DIAGNOSTICS (see Section 4-4 on page 4-8) Electronics checks

The Model 7003M Percent Oxygen Analyzer
is housed in a NEMA 4X (CSA enclosure 4),
corrosion resistant housing suitable for panel,
pipe or wall mounting.

The analyzer has a microprocessor controlled
keyboard for operation. Signals from the
remote oxygen and temperature sensors are
processed to compute real time oxygen
concentration corrected for temperature,
constant pressure differences and residual
sensor current. The oxygen concentration is
compared with user-set alarm parameters,
and also generates an isolated 4 to 20 or 0 to
20mA signal. Data is stored in a memory
circuit that retains the data in case power is
removed.

The analyzer is shipped from the factory
configured for operation on either 115 VAC or
230 VAC, 50/60 Hz as specified by the
customer when ordered.

output, automatic temperature compensation
circuitry, and dual relay contact closures for
alarms or ON/OFF control devices as
standard features. The alarm ranges can be
selected independently from the output range,
eliminating the need to readjust alarm
setpoints if the range is changed.

The analyzer has six modes of operation:

1-2 PRINCIPLE OF MEASUREMENT

Measurement is based on the electro­chemical reaction between oxygen and the
sensor cathode which produces a low level
electrical current. The sensor signal is
proportional to the partial pressure of oxygen
present at the membrane. This signal and a
thermistor signal are received by the analyzer
and processed by the electronics to output a
calibrated oxygen signal that is compensated
for temperature.

1-3 SENSORS

Rosemount Analytical offers rechargeable and
disposable oxygen sensors which can be
used with the Model 7003M. These sensors
are supplied in kits: Submersion, in-line flow,
fast response, and a cell separation kit.
Sensors are available constructed of
polypropylene or Ryton. See Section 7­4REPLACEMENT PARTS - SENSORS on
page 7-3, for additional information.

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Model 7003M

1-4 CONDITIONS AFFECTING MEASUREMENT

Oxygen measurement is affected by the
following:

•

Composition of the sampled gas

•

Sample and calibration gas pressures

•

Environment of sensor, cable and
analyzer

Each must be considered when calibrating
and operating the analyzer to obtain accurate
measurements.

a. Gas Composition

Any substance in the sample that
significantly interferes or "poisons" the
sensor oxygen reading should be
removed by a chemical and/or
mechanical sample handling system (see
Section 5-2 on page 5-1). If ambient air is
not used as the span gas, the
composition of calibration gases should
also be representative of the sample.

The sample and calibration gases must
meet certain specifications (see
Specifications in Preface) to ensure
accurate measurement. Physical
parameters that affect measurement
include:

b. Sample and Cal Gas Pressures

The sample and calibration gases may be
at different pressures as long as the
pressure of each remains constant. Any
variation in the pressure of either gas will
result in an incorrect output reading of the
same proportion.

Two methods of sample calibration are
recommended:

1. Calibrate at the sample pressure, or

2. Calibrated at a different pressure, and
enter the two pressure in the analyzer
(Section 4-2c on page 4-4)

Refer to Section 5-2 on page 5-1 for a
more detailed discussion of the
relationship between gas pressures and
apparent oxygen concentration.

c. Environmental Factors

If radio frequency interference (RFI)
normally occurs in the operating
environment, the sensor cable should be
electrically shielded during installation.

•

Pressure

•

Humidity

•

Temperature

•

Gas composition

Also refer to Section 5-2 on page 5-1 for
additional information about how gas
conditions affect the oxygen
measurement.

1-2 Description and Specifications Rosemount Analytical Inc. A Division of Emerson Process Management

Model 7003M

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1-5 FEATURES

Suppressed Ranges

When setting the Model 7003M to a
suppressed output range (15 to 25%, etc.),
note that the absolute accuracy, drift, and
noise of the oxygen measurement will remain
the same for all ranges (see Specifications in
Preface).

ALARM Mode

ALARM Mode is not self-resetting. Operator
must press ACK to bring relays back to their
no-alarm state. Used when immediate
operator action is required.

NOTE:

Operator Can Bypass Alarm Relays

When relays are set to ALARM Mode (Sec­tion 3-6a on page 3-16) and an alarm con­dition has occurred, pressing the ACK key
will turn off the relay switch, whether the
oxygen level is out of range or not. If you
do not want an operator to be able to by­pass the relay switches in this way, set the
instrument to ON/OFF -CONTROL Mode.

ON/OFF-Controller Mode

ON/OFF-CONTROLLER Mode is self­resetting. Pressing ACK has no effect on
relay coils. Used when automated action is
required.

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1-6 SPECIFICATIONS

a. Performance

Accuracy........................................ ±0.25% oxygen

Operating Range ........................... 0 to 25% oxygen (endpoints set by user)

Linearity ......................................... ±0.25% oxygen

Zero Stability.................................. ±0.25% oxygen/week at 25°C

Span Stability................................. ±0.25% oxygen/24 hours at 25°C

Noise ............................................. ±0.25% oxygen

Response Time ............................. 90% of reading in 20 seconds at 25°C

Temperature Effects

32 to 110°F (0 to 44°C) ......... ±6% reading

60 to 90°F (15 to 32°C) ......... ±3% reading

other 30°F (16°C) ranges ...... +4% reading

Model 7003M

(with constant sample temperature after sensor zero offset correc­tion)

b. Physical

Mounting

Standard ................................ Panel Mount

Optional ................................. Wall Mount, Pipe Mount

Dimensions.................................... 5.7 x 5.7 x 7.6 inches (14 x 14 x 19 cm) HxWxD

Weight ........................................... Approximately 3.0 pounds (1.36 kg)

Enclosure....................................... ABS Plastic, Black, NEMA Type 4X, IP65

Ambient Humidity .......................... 95% relative humidity, non-condensing (maximum)

Ambient Temperature.................... 14 to 122°F (-10 to 50°C)

Sensor Cable................................. 2 twisted pairs, specified length up to 1000 feet (305 m) maximum

Power Cable.................................. 3 conductor, Type SJT, 18 AWG minimum

Connection Conduit

Power..................................... 1/2 inch

Sensor ................................... 3/4 inch

1-4 Description and Specifications Rosemount Analytical Inc. A Division of Emerson Process Management

Model 7003M

c. Electrical

Power Requirements..................... 115/230 VAC ±10%, 50/60 Hz ±3 Hz

Display........................................... 3-1/2 digit liquid crystal (LCD)

Signal Output................................. Isolated 4 to 20 or 0 to 20 mA (selectable)

Alarm Relay Contacts.................... Two Form C Relays

Recorder Output............................ Isolated 4 to 20 mA

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600 ohms maximum load

SPDT, resistive load, independently adjustable
Deadband adjustable over full range
Alarm Relay Contacts Ratings
General Purpose (Ordinary) Locations:
115 VAC, 3.0 A (resistive), 230 VAC, 1.5 A resistive
Class I, Division 2 Locations:
CSA: 120 VAC, 3.0 A (non-inductive)
240 VAC, 1.5 A (non-inductive).
FM: 28 VDC (resistive) (Ci = 0, Li = 0)
Groups A&B: 150 mA
Group C: 400 mA
Group D: 540 mA

d. Sensors

Types............................................. Rechargeable and Disposable

Process Connections .................... Refer to flow chamber (if supplied)

Sample Pressure........................... 0 to 50 psig (0 to 345 kPa)

Sample Temperature..................... 32 to 110°F (0 to 44°C)

Ambient Temperature.................... 32 to 110°F (0 to 44°C)

Ambient Humidity .......................... 95% relative humidity, non-condensing (maximum)

Also refer to instructions supplied with sensor.

Rosemount Analytical Inc. A Division of Emerson Process Management Description and Specifications 1-5

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1-6 Description and Specifications Rosemount Analytical Inc. A Division of Emerson Process Management

Model 7003M

Operator Manual

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June 2002

SECTION 2

INSTALLATION

2-1 UNPACKING

Carefully examine the shipping carton and
contents for signs of damage. Immediately
notify the shipping carrier if the carton or
contents is damaged. Retain the carton and
packing material until all components
associated with the Model 7003M Percent
Oxygen Analyzer are operational.

2-2 STORAGE

The sensors and analyzer unit may be
shipped together or separately. The sensors
are shipped assembly and charged, ready for
use.

If rechargeable sensors are stored longer than
six months, they may need to be recharged or
rejuvenated if performance is marginal.
Disposable sensors are not rechargeable.

Refer to documentation supplied with sensors
for more information.

2-3 ANALYZER INSTALLATION

The Model 7003M Percent Oxygen Analyzer
is designed to meet NEMA Type 4X (CSA
enclosure 4) requirements, provided that the
cutouts in the bottom of the enclosure are
fitted with approved conduit fittings or are
properly sealed by the user with Hoffman
plugs (PN A-S050) or equivalent.

The Model 7003M is supplied with the Panel
Mounting Kit PN 652527 as standard.
Optional Wall Mount Kit PN 652539 and Pipe
Mount Kit PN 652529 are available. Refer to
the Outline and Mounting drawings provided
in the rear of this manual.

2-4 SENSOR INSTALLATION

NOTE:

Refer to Figure 2-1 Sensor Ordering Matrix
on page 2-2, and verify that the sensor to
be used corresponds with the application.
If an incorrect sensor is used, calibration
may be impossible or incorrect. If a differ­ent type of sensor is to be used, the rocker
switch (SW1) on the Signal Board may
have to be changed (see Section 2-4a
below).

Install the sensor in an area where
temperature is relatively constant, taking care
to avoid changes in exposure to sunlight or
due to sudden drafts. A room-temperature
environment is preferable. The flow
chamber/sensor kit contains detailed
mounting and sample flow information. Add
distilled or deionized water to the sensor to
the maximum level indication on the sensor
reservoir. Let sensor stand for approximately
15 minutes and check for leaks around the
base of the reservoir, and at the seams and
corners. If a leak is found, contact the factory
before proceeding. Drain the sensor.

a. Analyzer/Sensor Jumper Configuration

The Model 7003M is configured to match
the type of sensor ordered with the
analyzer. If the Signal Board or Sensor is
repaired or replaced, verify rocker switch
SW1 on the Signal Board is properly set.

Rechargeable Sensor: Close
positions 1, 4, and 5

Disposable Sensor: Close positions
2, 4, and 6

Rosemount Analytical Inc. A Division of Emerson Process Management Installation 2-1

Operator Manual

748223-K
June 2002

Model 7003M

4000 Rechargeable Sensor
5000 Disposable Sensor

1 Polypropylene
2 Ryton (rechargeable only)
9 Special (consult factory)

1 Submersion
2 In-Line Flow
3 Fast Response (rechargeable only)
9 Special (consult factory)

4 0 0 0 3

Position →

Positions 1 through 4 = Sensor Type
Position 5 = Material of Construction (Sensor and Flow Assembly)
Position 6 = Flow Assembly Configuration

Example 400013 is a Rechargeable sensor, constructed of polypropylene, mounted in a
Fast-Response Flow Chamber Assembly.

1234

Figure 2-1. Sensor Ordering Matrix

1

5

6

2-2 Installation Rosemount Analytical Inc. A Division of Emerson Process Management

Model 7003M

Operator Manual

748223-K

June 2002

2-5 ELECTRICAL CONNECTIONS

Observe all precautions stated in this manual
and in the drawings provided at the back of
this manual before installation.

All electrical connections to the analyzer are
made on the Power Supply Board connection
panel (see Figure 2-2 below and drawing

652683), which is accessed by removing the
rear cover.

WARNING

ELECTRICAL SHOCK HAZARD

Do not operate without rear cover secured.
Servicing requires access to live parts
which can cause death or serious injury.
Refer servicing to qualified personnel.

For safety and proper performance this in­strument must be connected to a properly
grounded three-wire source of power.

Electrical installation must be made in ac­cordance with the National Electrical Code
(ANSI/NFPA-70) and/or any applicable na­tional or local codes.

WARNING

ENCLOSURE INTEGRITY

Unused cable conduit entries must be se­curely sealed by non-flammable closures
to provide enclosure integrity in compli­ance with personnel safety and environ­mental protection requirements. For
watertight installation conforming to the
requirements of NEMA Type 4X, use
Hoffman plugs (PN A-S050) or equivalent
to seal any unused openings.

Provide three separate 1/2 inch conduits as
follows:

•

Power cable

•

Sensor cable

•

Alarm cables

1 +12V
2 -12V
1 ANODE
2 TEMP SENSE
3 NC
4 NC
5 EPOL
6 GND
7 Tx
8 Rx
9 RET
1 COM
2 NC
3 NO
4 COM
5 NC
6 NO
7 ISO GND
8 ISO CUR­9 ISO CUR+

ALARM CONTACT RATING:
3A 120 VAC

1.5A 240 VAC
3A 30 VDC

AC POWER

AL 1

AL 2

HOT NEUT GND

L1 L2

FUSE RATING:
115V: 1/4A
250V
230V: 1/8A
250V

Figure 2-2. Model 7003M Rear Panel Connections

Rosemount Analytical Inc. A Division of Emerson Process Management Installation 2-3

Operator Manual

748223-K
June 2002

a. Sensor Cable

The sensor cable used with the Model
7003M may be of any length up to a
maximum of 1000 feet (305 m). (See
Table 2-1 below.)

The signal cable should be routed through
a conduit (customer-supplied) in
permanent installations or in cases where
the sensor is located more than a few feet
from the control unit. (See Table 2-2
below.)

Model 7003M

Connect Sensor Cable

1. Ensure that power is disconnected
and remove rear cover.

2. Install the conduit or cable clamp in
the left opening in the bottom rear of
the case.

3. Install the sensor cable in the
instrument through the cable clamp
and tighten the nut on the plug to
create a seal around the cable.

NOTE:

In humid environments, temperature
changes can cause moisture to con­dense in the conduit, resulting in sig­nal noise and corrosion. To minimize
the effect of condensation, put desic­cant (available locally) inside the con­duit before sealing it.

CABLE PART

NUMBER

191748 10 Feet (3.1 m)
193265­SPECL

Table 2-1. Sensor Cables

If conduit used:

1/2 inch NPT female connection on
bottom of control unit. (Conduit cus­tomer-supplied.

If no conduit used:

Use cable connector assembly (PN

856831) to provide watertight seal. As­sembly includes: Aluminum inner seal­ing grommet for connector compression
nut.

Table 2-2. Analyzer Cable

Connections

LENGTH

Any specified length
up to 1000 Feet (305
m)

4. Refer to Figure 2-2 on page 2-3.
Using a flat-blade screwdriver,
connect the wires of the sensor cable
to the TB2-1, TB2-2, TB2-5 and TB2­6 on the rear panel of the analyzer.

5. Replace the rear cover if no other
connections are to be made. Do not
overtighten the cover retaining screws
to avoid stripping the threads in the
plastic case.

b. Power Connections

Electrical power is supplied to the
analyzer via a customer-supplied three
conductor cable, type SJT, minimum 18
AWG. Refer to the installation drawing in
the rear of this manual.

Jumpers and Fuses

To verify the jumper location for the
specified power (115 or 230 VAC) or if the
analyzer is to be connected to a different
power source, refer to Figure 2-3 on page
2-5and set jumpers and fuse as follows:

WARNING

ELECTRICAL SHOCK HAZARD

Disconnect power to analyzer before con­tinuing.

2-4 Installation Rosemount Analytical Inc. A Division of Emerson Process Management

Model 7003M

Operator Manual

748223-K

June 2002

WARNING

1. Remove the rear cover from the
analyzer.

2. Remove Power Supply Board.

3. Verify and/or set Jumpers E1, E2, E3,
and E4 per Figure 2-3 below.

4. Verify that fuse (F1) is correct for
power.

5. Re-install Power Supply Board.

6. Replace the rear cover if no other
connections are to be made. Do not
overtighten the cover retaining screws
to avoid stripping the threads in the
plastic case.

Conduit Connections

Route the power cable through conduit
and into the central opening in the bottom
of the case. The inlet hole is sized for
standard 1/2 inch conduit fittings.

ENCLOSURE NOT GROUNDED

The non-metallic enclosure does not pro­vide grounding between conduit connec­tions. Use grounding-type bushing and
jumper wires.

Connect Power Cable

Connect power wiring to the compression
type connectors on the rear panel (Figure
2-2 on page 2-3) as follows:

1. Loosen the connector screw.

2. Strip insulation back approximately
1/4 inch (6.35 mm), twist stranded
wires together. DO NOT tin braid
wire or the connection can work
loose.

3. Insert wire into connector about 1/4
inch (6.25 mm), ensuring that wires
do not touch any other wire or
connector.

4. Tighten screw.

115 VAC

Jumpers: E1 - E2
E3 - E4
Fuse: 1/4 Amp

115 VAC

Jumpers: E2 - E4
Fuse: 1/8 Amp

Power Supply Board

F1 E3 E4 E2 E1

1/4 AMP 115 VAC

F1 E3 E4 E2 E1

1/8 AMP 230 VAC

Figure 2-3. Power Jumpers and Fuses

Rosemount Analytical Inc. A Division of Emerson Process Management Installation 2-5